Aircraft continue to evolve using increasingly sophisticated technologies to achieve new goals in maneuverability, speed, distance and efficiency. Whether in military, commercial, or private applications, new aircraft designs are expected to perform in ways that were unfathomable just a short time ago.  But how can manufacturers possibly keep up with these expectations?

A leading manufacturer of flight critical products for the aerospace and defense industries had a major issue and CCS was able to solve the problem.

When developing a hydraulic actuation system for a new helicopter, they needed a pressure switch that was not only small and lightweight but could last 4 times longer than traditional technologies in a very dynamic high pressure environment.

Custom Control Sensors’ Innovative Solution

To accomplish this ambitious goal, CCS engineers started by understanding the shortcomings of traditional electromechanical pressure switches. From accuracy and environmental limitations to premature wear and contact degradation, CCS’s new electronic switch needed to solve all of these problems.

CCS’s new TRS-Series electronic pressure switch increases the operational cycles a pressure switch can provide in a high pressure dynamic environment by 4 times the traditional electromechanical pressure switch in a small lightweight design. 1,000,000 cycles or more. In addition, the electronic pressure switch eliminates contact resistance issues that can be experienced with switches using micro switches. The TRS-Series switch also incorporates patented¹ galvanic isolation to prevent the degrading effects of high dielectric and lightning.

CCS was able to produce an electronic switch that not only met but exceeded our customers’ expectations. They now had a pressure switch with an adjustable set point and dead-band that was smaller, more durable, and more accurate than other traditional electromechanical switches on the market.

Why Traditional Electromechanical Switches Could Not Meet the Needs of the New Helicopter

Traditional electromechanical pressure switches could not meet the required operational cycles of the new helicopter due to the degradation in the internal components such as the micro-switch.

This degradation over time causes set point drift and leads to eventual failure of the switch, typically within 350,000 cycles of operation in high-pressure dynamic systems.

Custom Control Sensors was challenged to come up with a practical solution. The first solution was to increase the size of the switch to allow the introduction of more substantial protective components. However, that was out of the question because of the restrictions on size and weight. The second solution was to create a compact electronic switch that could mimic a mechanical switch and would have an accurate, repeatable operation over the course of more than 1,000,000 cycles of operation. In addition, the electronic switch was required to have the same high-voltage resistance capabilities as a mechanical switch. Shortly after accepting the challenge, CCS set out to completely redesign and revolutionize the traditional pressure switch, which was not only small and lightweight but could last 4 times longer than traditional technologies.

Background on CCS’s Experience in the Aerospace Industry

Custom Control Sensors has more than 60 years of experience developing switches and sensors for the aerospace industry. This extensive experience has given us the industry knowledge and the capabilities needed to meet the growingly complex demands of our customers. CCS offers complete build-to-specification design, research and development, 3-D modeling, prototyping, manufacturing, testing, quality control, and after-sales support capabilities for the Aerospace, Defense, Industrial, and Energy industries across the globe.

For more information, take a look at our selection of pressure, temperature, and flow sensors and switches, or contact us directly.

¹ U.S. Patent Nos. 10,578,504; 10,876,915; 11,579,032.